EP3761021A1 - Computerimplementiertes verfahren und system zur zerstörungsfreien prüfung - Google Patents

Computerimplementiertes verfahren und system zur zerstörungsfreien prüfung Download PDF

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Publication number
EP3761021A1
EP3761021A1 EP19382565.0A EP19382565A EP3761021A1 EP 3761021 A1 EP3761021 A1 EP 3761021A1 EP 19382565 A EP19382565 A EP 19382565A EP 3761021 A1 EP3761021 A1 EP 3761021A1
Authority
EP
European Patent Office
Prior art keywords
time period
frequency response
frequency
eigenfrequency
computer
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP19382565.0A
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English (en)
French (fr)
Inventor
Jens Bold
Nieves Lapena
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Boeing Co
Original Assignee
Boeing Co
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Boeing Co filed Critical Boeing Co
Priority to EP19382565.0A priority Critical patent/EP3761021A1/de
Priority to CN202010617631.3A priority patent/CN112182832A/zh
Publication of EP3761021A1 publication Critical patent/EP3761021A1/de
Withdrawn legal-status Critical Current

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    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N29/00—Investigating or analysing materials by the use of ultrasonic, sonic or infrasonic waves; Visualisation of the interior of objects by transmitting ultrasonic or sonic waves through the object
    • G01N29/04—Analysing solids
    • G01N29/043—Analysing solids in the interior, e.g. by shear waves
    • G—PHYSICS
    • G06—COMPUTING; CALCULATING OR COUNTING
    • G06F—ELECTRIC DIGITAL DATA PROCESSING
    • G06F30/00—Computer-aided design [CAD]
    • G06F30/20—Design optimisation, verification or simulation
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01M—TESTING STATIC OR DYNAMIC BALANCE OF MACHINES OR STRUCTURES; TESTING OF STRUCTURES OR APPARATUS, NOT OTHERWISE PROVIDED FOR
    • G01M5/00—Investigating the elasticity of structures, e.g. deflection of bridges or air-craft wings
    • G01M5/0066—Investigating the elasticity of structures, e.g. deflection of bridges or air-craft wings by exciting or detecting vibration or acceleration
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01M—TESTING STATIC OR DYNAMIC BALANCE OF MACHINES OR STRUCTURES; TESTING OF STRUCTURES OR APPARATUS, NOT OTHERWISE PROVIDED FOR
    • G01M7/00—Vibration-testing of structures; Shock-testing of structures
    • G01M7/02—Vibration-testing by means of a shake table
    • G01M7/022—Vibration control arrangements, e.g. for generating random vibrations
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01M—TESTING STATIC OR DYNAMIC BALANCE OF MACHINES OR STRUCTURES; TESTING OF STRUCTURES OR APPARATUS, NOT OTHERWISE PROVIDED FOR
    • G01M7/00—Vibration-testing of structures; Shock-testing of structures
    • G01M7/02—Vibration-testing by means of a shake table
    • G01M7/025—Measuring arrangements
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01M—TESTING STATIC OR DYNAMIC BALANCE OF MACHINES OR STRUCTURES; TESTING OF STRUCTURES OR APPARATUS, NOT OTHERWISE PROVIDED FOR
    • G01M7/00—Vibration-testing of structures; Shock-testing of structures
    • G01M7/02—Vibration-testing by means of a shake table
    • G01M7/027—Specimen mounting arrangements, e.g. table head adapters
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01M—TESTING STATIC OR DYNAMIC BALANCE OF MACHINES OR STRUCTURES; TESTING OF STRUCTURES OR APPARATUS, NOT OTHERWISE PROVIDED FOR
    • G01M7/00—Vibration-testing of structures; Shock-testing of structures
    • G01M7/02—Vibration-testing by means of a shake table
    • G01M7/06—Multidirectional test stands
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N29/00—Investigating or analysing materials by the use of ultrasonic, sonic or infrasonic waves; Visualisation of the interior of objects by transmitting ultrasonic or sonic waves through the object
    • G01N29/04—Analysing solids
    • G01N29/045—Analysing solids by imparting shocks to the workpiece and detecting the vibrations or the acoustic waves caused by the shocks
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N29/00—Investigating or analysing materials by the use of ultrasonic, sonic or infrasonic waves; Visualisation of the interior of objects by transmitting ultrasonic or sonic waves through the object
    • G01N29/04—Analysing solids
    • G01N29/11—Analysing solids by measuring attenuation of acoustic waves
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N29/00—Investigating or analysing materials by the use of ultrasonic, sonic or infrasonic waves; Visualisation of the interior of objects by transmitting ultrasonic or sonic waves through the object
    • G01N29/04—Analysing solids
    • G01N29/12—Analysing solids by measuring frequency or resonance of acoustic waves
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N29/00—Investigating or analysing materials by the use of ultrasonic, sonic or infrasonic waves; Visualisation of the interior of objects by transmitting ultrasonic or sonic waves through the object
    • G01N29/22—Details, e.g. general constructional or apparatus details
    • G01N29/223—Supports, positioning or alignment in fixed situation
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N29/00—Investigating or analysing materials by the use of ultrasonic, sonic or infrasonic waves; Visualisation of the interior of objects by transmitting ultrasonic or sonic waves through the object
    • G01N29/44—Processing the detected response signal, e.g. electronic circuits specially adapted therefor
    • G01N29/4409—Processing the detected response signal, e.g. electronic circuits specially adapted therefor by comparison
    • G01N29/4427—Processing the detected response signal, e.g. electronic circuits specially adapted therefor by comparison with stored values, e.g. threshold values
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N29/00—Investigating or analysing materials by the use of ultrasonic, sonic or infrasonic waves; Visualisation of the interior of objects by transmitting ultrasonic or sonic waves through the object
    • G01N29/44—Processing the detected response signal, e.g. electronic circuits specially adapted therefor
    • G01N29/4409—Processing the detected response signal, e.g. electronic circuits specially adapted therefor by comparison
    • G01N29/4436—Processing the detected response signal, e.g. electronic circuits specially adapted therefor by comparison with a reference signal
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N2291/00—Indexing codes associated with group G01N29/00
    • G01N2291/26—Scanned objects
    • G01N2291/269—Various geometry objects
    • G01N2291/2694—Wings or other aircraft parts
    • G—PHYSICS
    • G06—COMPUTING; CALCULATING OR COUNTING
    • G06F—ELECTRIC DIGITAL DATA PROCESSING
    • G06F2111/00—Details relating to CAD techniques
    • G06F2111/10—Numerical modelling

Definitions

  • the present disclosure relates generally to techniques for nondestructive inspection of structural components and, more particularly to quality control systems and methods for detecting structural damage in a part of a structure using frequency response.
  • 3D printing is also called additive manufacturing (AM) which may be defined as a process of joining materials to make objects from Computer Aided Design (CAD) model data, usually layer upon layer, as opposed to subtractive manufacturing methods.
  • AM additive manufacturing
  • the AM components are normally inspected using x-ray techniques or computer tomography. Such techniques require expensive equipment and complicated procedures. This makes inspections laborious, difficult, and expensive. Furthermore, certain micro fractures might not be found during x-ray or computer tomography due to the resolution of the systems.
  • liquid penetrant techniques could be used. However, these have to be performed manually by operators. They are time-consuming and depend on the skills and experience of a particular operator. Dye penetrant is a commonly used method for metha maschined and fasted part but also here, small cracks - especially when thermal stresses induce compression loads in the cracks - may not be easily found by human manual inspection.
  • the component is an additive manufactured part that is manufactured layer by layer using a welding process with lasers, thermal stresses will occur inside the part and may induce micro cracks where existing inspection techniques are less suitable since they are either expensive due to the equipment or labor intensive due to manual work.
  • a method and a system for detecting micro fractures of a part by using Eigenfrequencies may be disclosed herein.
  • a computer-implemented method for nondestructive inspection of a part of a structure is disclosed.
  • the computer-implemented method can include vibrating the part, measuring vibration frequencies of the part using a sensor unit comprising one or more microphones, obtaining a first frequency response of the part and identifying at least one Eigenfrequency in the first frequency response, comparing the at least one Eigenfrequency with an expected vibration frequency and obtaining a difference therebetween, and determining that the part is defective based on the difference between the Eigenfrequency and the expected vibration frequency.
  • a system for nondestructive inspection of a part of a structure can include an acoustic chamber configured to receive the part, a sensor unit coupled to the acoustic chamber and configured to measure vibration frequencies of the part to obtain a frequency response of the part and to identify at least one Eigenfrequency in the frequency response, and a processing unit.
  • the processing unit can be configured to compare the at least one Eigenfrequency with an expected vibration frequency to obtain a difference therebetween and identify the part as defective based on the difference.
  • Various examples illustrate techniques for inspecting and diagnosing a part of a structure, like an aircraft. It is proposed using different measuring devices to measure the frequency on the part of the structure and measured at two separate time intervals. Without limitation, the various examples are referred to AM parts. Yet the techniques disclosed are equally valid for other sort of industrial components.
  • the proposed techniques utilize the characteristic that similar non-defective parts produce very similar frequency responses. However, if one of the parts is defective, e.g. due to a crack, the frequency response changes dramatically. While factors like temperature or humidity might influence, they do so in an insignificant amount.
  • a frequency response can be calculated by finite element analysis before the first AM part is even built. Additionally or alternatively, the obtained frequency response can be obtained with real measurements.
  • the present disclosure proposes a method and a system for an inexpensive and safe technique of detecting micro fractures of a part by using Eigenfrequencies. Furthermore, in particular, it allows an environmental friendly procedure to be advantageously implemented in serial production of additive manufacturing (AM) parts but also during maintenance. It can be used in many fields. For instance, in aerospace for all structures and interior (furniture, interior, seats, etc.) but also in automotive, wind energy, sports articles, etc.
  • AM additive manufacturing
  • An Eigenfrequency should be understood as a frequency at which a system tends to oscillate in the absence of any driving or damping force.
  • the present disclosure can include scanning Eigenfrequencies of a part, in particular an AM part, obtaining a frequency response representative of the part, comparing the frequency response of a part with an expected frequency response using numerical analysis from finite element calculations or real measurements.
  • the expected frequency response can be obtained applying numerical analysis and finite element calculations from a similar part that is known to be free of defects, like micro fractures, faults, etc. This is referred to as an original part. Note that a reduction of local stiffness in a component causes a variation of one or more Eigenfrequencies. Consequently, the frequency response can be used as a signature that identify that, in the part, the geometry and/or stiffness is not distributed in a correct way.
  • frequency responses can be obtained defining two separate time periods for performing measurements to the part, one, as new part, before being used and, two, after the part has been used.
  • the part should be properly placed. For instance by laying on a plate, hanging on a hook or fixed at a support, among other possibilities.
  • the placing of the part can be either done before or inside a measurement acoustic chamber suitable for frequency response measurements.
  • This acoustic chamber can be either equipped with or without acoustic damping.
  • the measurements performed by a sensor unit can be either done with microphone or other suitable devices like piezo-electrical devices to measure the frequency response of, for instance, a new or used part. These devices of the sensor unit can be inside or outside the chamber.
  • FIG. 1A shows an example of an original AM part 6 , which is known to be free of defects. This can be an AM part before installation on a structure like an aircraft, a vehicle, a wind generator, etc.
  • AM part 6 can, in certain examples, be an AM part with AM process remains (e.g., flash) cleaned.
  • FIG. 1B shows, on the other hand, an example of a defective non-original AM part 2 , which includes a micro fracture 4 .
  • FIG. 2A shows several images of an example of an original AM part 6 and a defective non-original AM part 2 , scanned in a first set of frequencies 1-5.
  • FIG. 2B shows several images of the original AM part 6 and the defective non-original part 2 scanned in a second set of frequencies 6-10.
  • FIGs. 2A and 2B there are different areas present in the original AM part 6 and in the non-original AM part 2 .
  • the different areas can be scanned through a plurality of operations, but other examples can scan the part 2 or 6 as a whole in one operation.
  • These different areas referred to as displacement distribution regions 8 , return different values for the normalized vibration amplitude when scanned, depending on the vibration frequency of the scanning. Displacement distribution regions 8 are illustrated in dotted line.
  • the frequency response should be the same as in the original AM part 6 .
  • the displacement distribution regions 8 in both parts 2 , 6 do not match for one or more frequencies. This outcome can serve to trigger maintenance indications, scheduling of further evaluation, or replacement or repair, if feasible, of the defective non-original AM part 4 .
  • they can provide useful information in view of their properties, such as elongated extension or changes in shape over time, to be associated with a specific type of defect in an AM part. Generally, the higher the displacement, the weaker the AM part in that region.
  • different thresholds can be defined to define several levels of defectiveness.
  • vibration amplitude value is useful but the corresponding value of vibration frequency as well.
  • Defective non-original AM part 2 can normally be observed to give a response with higher frequency (weaker) and a fault with lower frequency (more damping) due to the crack.
  • the set of frequencies typically used are chosen depending on several aspects such as the material used, the geometry of the part, and the distribution of stiffness within the part.
  • Each design will have its typical frequency response, which can be calculated in advance with finite element modelling methods. Based on these results, the frequency range can be adjusted.
  • FIG. 3 shows is a graphical representation of the sets of frequency responses corresponding to FIGs 2A and 2B .
  • there are overlapping pulses at certain vibration frequencies which indicates the response is the same in both AM parts.
  • frequencies f 4 to f 10 of the failed part are shifted with respect to the original part f' 4 to f' 10 .
  • several normalized vibration amplitudes do not occur at an expected frequency f' i .
  • Each part has its own frequency response spectrum. Consequently, this can imply that tested non-original AM part 2 is defective. This serves as a signature of the part.
  • a first option is using an original AM part 6 free of defects (e.g., for first article inspection soon after production of the part).
  • Another option relates to using the same non-original AM part and measuring the AM part at different moments throughout its lifetime, thus defining inspection intervals and analyzing its evolution.
  • the signature of the AM part can be defined and saved and used as a base response to detect a structural defect later in the part's service life by measuring at the same vibration frequency and comparing the responses.
  • a micro fracture 6 or similar failures can be detected later, when the frequency response changes at subsequent inspection intervals.
  • FIG. 5A a measuring device is shown.
  • the measuring device comprises an acoustic chamber 52 with internal damper 54 and a handle 56 for securing a part 2.
  • FIG. 5B illustrates the same acoustic chamber 52 without an internal damper.
  • internal dampers can be useful in allowing the part to accurately transition between frequencies without vibrations resulting from analysis at a first frequency affecting the behavior of the part at a second frequency.
  • Microphones can be installed inside or outside the acoustic chamber 52 forming a sensor unit. The AM part to be tested is placed in the acoustic chamber 52 using any of the arrangements depicted in FIGs. 4A-4C .
  • FIG. 6 shows a flow diagram of several steps of an overall example of a method.
  • a geometrical measuring step 62 is performed using 3D techniques. This step obtains the outside geometry of the manufactured part.
  • the numerical calculation can be updated to the manufactured geometry including acceptable tolerances and a frequency response analysis can be performed using finite element methods (FEM) in step 60 .
  • the frequency response analysis can determine the Eigenfrequencies of the AM part. These Eigenfrequencies are the frequency response of an AM part without defects.
  • the frequency response analysis can be performed after updating of the FEM geometry based on the measurements from step 62 .
  • the FEM frequency response analysis can be performed based on an AM part such as original AM part 6 or a particular non-original AM part 2 that is known to be free of defects.
  • the updated frequency response analysis performed in step 60 based on the results of step 62 can be performed to obtain more accurate base data for later analysis of the AM part 2 .
  • an arranging step 64 can be performed to prepare an AM part for measuring frequency response.
  • the AM part 2 is hung, clamped, simply rested, or otherwise held as indicated in FIGs. 4A-4C .
  • a placing step 66 is then performed to present the part for measuring of a frequency response of AM part 2.
  • the AM part 2 is thus placed inside of an acoustic chamber as indicated in FIGs. 5A-5B .
  • the acoustic chamber can include acoustic damping or can be without acoustic damping.
  • An acoustic measuring step 68 is then performed to measure the frequency response.
  • the measurement can be performed by, for example, vibrating the AM part 2 and measuring the vibration with external or internal microphones or by scanning the part and determining the Eigen-frequencies.
  • Such a measurement can also be performed of the part beforehand (e.g., on the original part as manufactured) and comparing the result of this original scanning to a later scanning (such as that performed in step 68 ) at a later inspection interval to detect if one or more micro fractures 4 have formed since the last inspection or the original inspection by extracting modulation differences.
  • a user or a computer controlled analyzer can determine the presence of one or more fractures 4 .
  • the frequency response analysis results from step 60 can be compared to the frequency response measured in step 68 . If the frequency response measured in step 68 substantially differs from that of the frequency response analysis results of step 60 , the presence of one or more fractures 4 can further be determined.
  • FIG. 7 shows a high-level block diagram of an overall example of a system.
  • FIG. 7 illustrates a system that includes a processing unit 70 communicatively coupled (e.g., above to receive data signals from and provide data signals to) to sensor unit 76 .
  • Sensor unit 76 can include one or more microphones.
  • Sensor unit 76 is coupled to acoustic chamber 52 .
  • sensor unit 76 is disposed within or outside of acoustic chamber 52 and able to detect vibrations of part 2 within acoustic chamber 52 .

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  • Physics & Mathematics (AREA)
  • General Physics & Mathematics (AREA)
  • Immunology (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Pathology (AREA)
  • General Health & Medical Sciences (AREA)
  • Biochemistry (AREA)
  • Analytical Chemistry (AREA)
  • Chemical & Material Sciences (AREA)
  • Health & Medical Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Acoustics & Sound (AREA)
  • Theoretical Computer Science (AREA)
  • Signal Processing (AREA)
  • Computer Hardware Design (AREA)
  • General Engineering & Computer Science (AREA)
  • Evolutionary Computation (AREA)
  • Geometry (AREA)
  • Aviation & Aerospace Engineering (AREA)
  • Investigating Or Analyzing Materials By The Use Of Ultrasonic Waves (AREA)
  • Measurement Of Mechanical Vibrations Or Ultrasonic Waves (AREA)
EP19382565.0A 2019-07-03 2019-07-03 Computerimplementiertes verfahren und system zur zerstörungsfreien prüfung Withdrawn EP3761021A1 (de)

Priority Applications (2)

Application Number Priority Date Filing Date Title
EP19382565.0A EP3761021A1 (de) 2019-07-03 2019-07-03 Computerimplementiertes verfahren und system zur zerstörungsfreien prüfung
CN202010617631.3A CN112182832A (zh) 2019-07-03 2020-07-01 用于非破坏性检查的计算机实现的方法和系统

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
EP19382565.0A EP3761021A1 (de) 2019-07-03 2019-07-03 Computerimplementiertes verfahren und system zur zerstörungsfreien prüfung

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EP3761021A1 true EP3761021A1 (de) 2021-01-06

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EP19382565.0A Withdrawn EP3761021A1 (de) 2019-07-03 2019-07-03 Computerimplementiertes verfahren und system zur zerstörungsfreien prüfung

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Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2122320A1 (de) * 2007-02-22 2009-11-25 Micro Motion, Inc. Vibrations-pipeline-diagnosesystem und verfahren
US20170138906A1 (en) * 2015-11-13 2017-05-18 Honeywell Fed Mfg & Tech Llc System and method for inspecting parts using frequency response function
EP3170591A1 (de) * 2015-11-19 2017-05-24 General Electric Company Echtzeitvibrationsüberwachung eines generativen fertigungsverfahrens

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2122320A1 (de) * 2007-02-22 2009-11-25 Micro Motion, Inc. Vibrations-pipeline-diagnosesystem und verfahren
US20170138906A1 (en) * 2015-11-13 2017-05-18 Honeywell Fed Mfg & Tech Llc System and method for inspecting parts using frequency response function
EP3170591A1 (de) * 2015-11-19 2017-05-24 General Electric Company Echtzeitvibrationsüberwachung eines generativen fertigungsverfahrens

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